Automated Machine Commissioning via Virtual Model Validation
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Solution Overview
Problem
Current methods for commissioning and updating machines in a series are inefficient and require manual configuration, lacking automation and precision, leading to increased time and risk during the process.
Innovation Solution
A method and system that generate an executable software package using a hierarchical step tree, allowing for automated commissioning by structuring data and information in a product data management system, enabling dynamic processing and conditional execution of steps, and enabling centralized configuration and parameterization of machine parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual configuration methods are used for commissioning machines, then flexibility in handling different machine configurations is maintained, but the commissioning time and risk of errors increase significantly
Solution Approach 1:
The patent creates a virtual copy of the machine's configuration data structure (XML-based machine model) that mirrors the physical machine's hierarchy and parameters. This digital twin can be automatically processed and validated before being transferred to the actual machine, enabling automated commissioning while maintaining accuracy through the precise copying of configuration data from the virtual to physical system.
Solution Approach 2:
The system performs preliminary validation and configuration checks in the virtual machine model before actual commissioning. The configuration data is prepared, validated for consistency, and pre-processed in the virtual environment, allowing errors to be detected and corrected before they affect the physical machine, thereby reducing commissioning time and error rates.
2Loss of time
If automated creation methods are used for generating control programs, then commissioning time is reduced, but the complexity of the system increases
Solution Approach 1:
The patent segments the commissioning system into distinct modular components: a virtual machine model creator, a configuration data generator, a validation module, and an automated transfer mechanism. Each module performs a specific function and can be independently developed and maintained, reducing overall system complexity while enabling automation. The hierarchical XML structure also segments machine configuration data into manageable sections.
Solution Approach 2:
The patent introduces an intermediary virtual machine model that acts as a mediator between the physical machine and the commissioning system. This virtual model serves as an intermediate representation that simplifies automated processing while maintaining fidelity to the actual machine's configuration, thereby reducing the complexity of direct automated control program generation.
3Adaptability or versatility
If comprehensive configuration data is collected for all machine series, then adaptability to different machine configurations is improved, but the amount of data to be processed increases
Solution Approach 1:
The patent applies local quality by creating specific instances of machine models tailored to each particular machine configuration within the series. Rather than processing all possible configurations uniformly, the system generates and processes only the configuration data relevant to the specific machine instance being commissioned, reducing data volume while maintaining full adaptability to different configurations through the standardized hierarchical structure.
Data Source
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AI summary
The method involves automatically generating a software packet in a projection system (12) depending on a step tree (28), where the step tree is formed as a graph with edges and nodes. The nodes comprise data and/or information for operating a machine, and the edges describe permitted transitions between the nodes. The software packet is executed in a machine or a unit communicatively connected with the machine, and the nodes represent executable operating steps that are activated or deactivated. Independent claims are also included for the following: (1) a computer program comprising program code instructions for executing a method for operating a machine (2) a storage medium comprising a computer program for executing a method for operating a machine (3) a projection system comprising a unit for producing a software packet.